Integrated engine welder and electric compressor

ABSTRACT

An integrated welder, generator and compressor unit that includes a housing that at least partially contains components of a welder, generator and an electric compressor. An engine, an electric current generator, and an electric air compressor are at least partially mounted in the housing. The electric current generator is at least partially connected to the engine to be at least partially driven thereby. The electric air compressor can be at least partially powered by the electric current generator during the operation of the engine. Alternatively, the air compressor can be powered by an external source of power without the use of the engine/generator.

INCORPORATION BY REFERENCE

Assignee's U.S. patent application Ser. No. 10/390,436 filed Mar. 17,2003 is incorporated herein and illustrates one type of integratedwelder, generator and compressor unit.

The present invention relates generally to engine driven weldingmachines, and more particularly to a welder/generator and compressorunit that can be transported to a site for welding and/or for operatingair and/or electric power tools.

BACKGROUND OF TEE INVENTION

Engine driven welding machines include a gas powered engine to run agenerator which supplies power to the welding electrode. Two such enginewelders are disclosed in U.S. Pat. Nos. 6,296,027 and 6,172,332, both ofwhich are incorporated herein by reference. The generator can also beused to operate other electrical equipment (e.g., lights, pumps, etc.).On a construction site, welding equipment and other types of equipmentare commonly used. The engine driven welder is commonly used to provideelectrical power to electric welders, lights, power tools, etc. Airpowered tools are also commonly used at a construction site. Such toolsare typically powered by a separate air compressor.

While both of these units have satisfactorily provided power to varioustools at construction sites, the use of both an air compressor and anengine driven welder has some disadvantages. Although the engine welderand air compressor are portable, it is nevertheless difficult and timeconsuming to load and unload these two separate units, and then positionand setup the various components which are to be used with such units.In addition, the two separate units require a certain amount of space ina transport vehicle, thus can result in multiple vehicles having to beused to transport all the components associated with the two units.Furthermore, some air compressors are powered by electricity. When suchelectric compressors are used at a work site, the air compressor may beplugged into and powered by the generator of the engine welder, thusreducing the available power for use with other power tools.

In an effort to address the past problems associated with the use of aseparate engine welder and air compressor, a self contained integratedwelder/generator and compressor is disclosed in U.S. Pat. No. 6,051,809,which is incorporated herein by reference. The '809 patent discloses aself-contained and fully integrated welder/generator and compressor unitthat is capable of being loaded onto and carried by a pickup truck. Thewelder/generator and compressor unit include a housing having a lengththat generally corresponds to the width of a pickup truck and having avertical height for receiving and containing components of thewelder/generator and compressor unit (e.g., compressor, generator,welder electronics, engine, fuel tank, etc.). An engine and anelectrical current generating alternator are mounted within the housingof the welder/generator and compressor unit. The electrical currentgenerating alternator is connected to the engine to be driven thereby,and the alternator includes an output drive shaft that drives a beltwhich in turn powers an air compressor. The housing includes an outputpanel that includes electrical outlets, welding lead receptacles, aircompressor outlets, etc.

Although the '809 patent addresses some of the disadvantages associatedwith a separate engine welder and air compressor, several problems stillremain. The housing of the welder/generator and compressor unit isspecifically designed to fit in the rear of a pickup truck. If thepickup truck cannot be positioned near a particular work site, thewelder/generator and compressor unit must be removed from the pickuptruck and carried to the particular work site. Furthermore, the '809patent discloses that the air compressor is connected to the shaft ofthe alternator by a belt which can require periodic maintenance. Inaddition, belt drives typically include a crankshaft pulley(s) and mayuse a magnetic clutch to control the belt drive. These components have atendency to quickly wear out, thereby requiring periodic maintenance.

Another engine welder and air compressor is disclosed in United StatesPatent Application Publication No. 2003/155,339 published on Aug. 21,2003 entitled “Screw air compressor for a welder”, which is incorporatedherein by reference. The '399 patent publication discloses welder havingan internal screw air compressor that is belt driven by the engine inthe housing of the engine welder. The engine is designed to work inconjunction with a has a pulley arrangement connected by belts to drivethe screw air compressor, an alternator, and an engine cooling fan. Aclutch assembly connected to the screw air compressor to control thescrew air compressor. As previously discussed, such an arrangement tendto quickly wear out, thereby require periodic maintenance.

Assignee's U.S. patent application Ser. No. 10/390,436 filed Mar. 17,2003 discloses an integrated welder and compressor unit that overcomesthe past problems with these prior welder and compressor units. Theintegrated engine driven welder and compressor unit disclosed in the'436 patent application can be conveniently transported to a site forwelding, operating air and/or electric power tools, and is more easilyoperated and maintained by a user. The integrated engine driven welderand compressor unit disclosed in the '436 patent application disclosesan air compressor connected to the drive shaft of the engine and/orelectrical alternator by a gear box. The gear box can have a single gearratio or multiple gear ratios to thereby control the desired speed ofthe compressor. The use of the gear box eliminates the need for a beltthat must be periodically replaced and/or the tension being periodicallyadjusted as was required in prior art designs. The use of the gear boxalso allows the speed of the compressor to be better controlled. The useof the gear box typically simplified and/or reduced the spacerequirements needed to connect the compressor to the drive shaft of theengine and/or electrical alternator, thus simplifying the assembly ofthe integrated welder/generator and compressor unit by reducing thenumber of components needed to connect the gear box between the aircompressor and the engine and/or electric current generator. The use ofthe gear box also resulted in reduced cost due to the simpler design andfewer parts. The use of the gear box further resulted in lessmaintenance since the gear box is more durable than a belt and pulleysystem, especially one that utilizes one or more clutches.

Although the integrated engine driven welder and compressor unitdisclosed in the '436 patent application was a significant improvementover prior art integrated engine driven welder and compressor units, theuse of a gear box to drive the compressor unit limits the location inwhich the compressor can be positioned in the housing of the enginewelder. In order to minimize the space and positioning limitationswithin the welder housing, special or more complex gearing arrangementsare required. Air compressors that are powered by gears are alsotypically more expensive than electric powered air compressors due tothe more complex design of the gear and belt powered compressors.

In view of the limitations of integrating a gear powered air compressorwith an engine welder, there remains a need for an integrated enginedriven welder and compressor unit that can provide both electrical powerand air pressure for use by various types of tools at a work site, thatenables the air compressor to be ergonomically positioned within thehousing of the engine welder, and that simplifies the design and reducesmanufacturing cost for the integrated engine driven welder andcompressor unit.

SUMMARY OF THE INVENTION

The present invention is directed to an integrated engine driven welderand compressor unit that can be conveniently transported to a site forwelding and/or for operating air and/or electric power tools, and can byoperated and maintained by a user.

In accordance with one aspect of the present invention, there isprovided a self-contained and fully integrated welder/generator andcompressor unit. The integrated welder/generator and compressor unit isprovided with a housing to protect the internal components of thewelder. At least partially protected by the housing is a fuel poweredengine and an electric generator. The fuel powered engine runs theelectric generator which in turn produces electricity for the arcwelder. The electric generator is selected to produce electricity forvarious types of arc welders such as, but not limited to, TIG welders,plasma arc welders, SAW welders, MIG welders, STT and other waveformwelders. Electric circuitry can be included within the housing tocontrol the amount of current, voltage, power and/or the waveform ofcurrent directed to the electrode of the welder. A fuel tank istypically provided within the housing to supply fuel to the fuel poweredmotor. The fuel tank can be positioned in various areas within thehousing, but is generally positioned at or near the base of the housingor engine welder. A filler tube is typically connected to a portion ofthe fuel tank and extends upwardly from the fuel tank and through aportion of the housing to enable an operator to refill the fuel tank.The filler tube and fuel tank can be made from one or multiple pieces ofmaterial. The filler tube and fuel tank are typically made of a durablematerial such as, but not limited to, plastic and/or a metal material.The engine welder typically includes a control panel to operate variousinternal components of the welder and/or to provide connectors tovarious components of the welder. A fixed or adjustable exhaust pipe forthe fuel power engine can be included on the engine powered welder.These and other standard components of an engine driven welder aredisclosed in U.S. Pat. Nos. 6,172,332; 6,263,926 and 6,296,027, whichare incorporated herein by reference. The engine welder housing can alsoinclude one or more storage compartments and/or holders adapted to storeand/or hold various welding tools, air tools, maintenance tools,electrodes, coolant, gas cylinders and/or other supplies on or withinthe housing. One non-limiting arrangement of the one or more storagecompartments and/or holders that can be used is disclosed in U.S. Pat.No. 6,596,972, which is incorporated by reference. The engine welder canbe transported by a welding carriage; however, this is not required. Onenon-limiting welding carriage which can be used is disclosed inAssignee's U.S. patent application Ser. No. 09/411,106, filed Oct. 4,1999, which is incorporated herein by reference. The engine poweredwelder can also include a filler tube and fuel tank arrangement thatincludes a fuel gauge to monitor the fuel level in the filler tubeand/or fuel tank; however, this is not required. The fuel gauge, whenused, enables an operator to monitor fuel levels within the filler tubeand/or fuel tank to enable an operator to anticipate when the enginewelder needs to be refueled and/or to notify an operator during therefueling process of the fuel tank when the fuel tank is filled, therebyavoiding spillage and waste of fuel. The minimizing of spillage canreduce damage to the welder and/or components about the welder, and thetime and money required for clean-up of the spilled fuel. Onenon-limiting configuration of the filler tube and fuel tank that can beused is disclosed in U.S. Pat. Nos. 6,172,332; 6,263,926; 6,296,027; and6,619,337, which are incorporated herein by reference. A grommet orinsert can also be used in the fueling cavity of the housing. Thegrommet or insert, when used, is designed to at least partially seal theregion about the fueling cavity to inhibit and/or prevent fluids fromentering the interior of the housing. One non-limiting configuration ofa grommet or insert that can be used is disclosed in U.S. Pat. Nos.6,172,332; 6,263,926; 6,296,027; and 6,619,337. In one embodiment of theinvention, the air compressor that is at least partially positioned inthe housing can be connected to the engine (e.g. drive shaft, auxiliaryshaft, etc.) and/or electrical alternator in the housing. Many types ofair compressors can be used (e.g., piston or reciprocating compressors,rotary or screw compressors, centrifugal or axial compressors, etc.).The air compressor can have a compressed air outlet mounted to thehousing. Unlike the connection disclosed in U.S. Pat. No. 6,051,809 orAssignee's U.S. patent application Ser. No. 10/390,436 filed Mar. 17,2003, the air compressor is an electric air compressor that can bepowered by the current generated by the electrical alternator in theengine welder housing and/or powered by an external power source (e.g.electrical outlet in a building, a portable electrical generator, etc.).

In accordance with another and/or alternative aspect of the presentinvention, the electric air compressor can be ergonomically positionedwithin the housing of the engine welder. The use of an electric poweredcompressor as opposed to a belt driven or gear driven compressor enablesthe compressor to be positioned in a variety of locations in the enginewelder housing. In the past, the position of the compressor was in partlimited to the location of the belt or gearing arrangement used to drivethe compressor. The present invention overcomes this disadvantage ofpast configurations for integrated engine welder and compressors. Theelectric powered compressor can be positioned anywhere in the housingthat has sufficient space for the compressor. The versatility ofpositioning the air compressor in the welding housing significantlyimproves the ease of design of the engine welder and compressor.

In accordance with still another and/or alternative aspect of thepresent invention, the electric air compressor is partially or fullypowered by the electric generator of the engine welder. During theoperation of the engine welder, the engine drives an electric generatorto create an electrical current that is used to power a particular arcwelding process. The engine welder typically includes one or morecircuits to provide standard 120V and/or 240V AC power. Commonly, theexterior of the housing will include one or more outlets that allows oneor more external electrical devices to be plugged into the engine welderand to be powered by the engine welder during the operation of theengine in the engine welder. The electric air compressor can beelectrically connected to the current from the one or more powercircuits of the engine welder so as to be supplied with power by theengine welder when the electric generator is being powered by the enginein the engine welder. In one embodiment, the housing of the enginewelder includes a switch used to activate and deactivate the electricair compressor. The switch allows the operator to only activate theelectric air compressor when needed. The activation/deactivation oron/off switch for the electric air compressor is typically located onthe front face of the engine welder where many of the other controlknobs and/or switches are located; however, the activation/deactivationor on/off switch for the electric air compressor can be located in otherareas on the engine welder.

In accordance with yet another and/or alternative aspect of the presentinvention, the electric air compressor is partially or fully powered byan external power source. In this aspect of the invention, the electricair compressor can be powered by an external power source so that theengine in the engine welder does not have to run every time the aircompressor needs to be used. There may be times that the air compressoris needed and no welder operation is required. In these situations, itcan be advantageous to run the air compressor off of an external powersource without having to run the engine welder engine. The running ofthe engine welder engine produces significantly greater power thanrequired by the air compressor. As such, running the engine welderengine to only supply power to the air compressor results in a waste ofenergy and unwanted wear of the other components of the engine welder.It is not uncommon at a construction site to have access to power fromstandard transmission lines. When available, power from thesetransmission lines is more than adequate to power the compressor. Theelectrical connector for the air compressor to receive external powercan be built into the housing of the engine welder (e.g., front panel)or be an electrical cord that hangs from the welder housing or is storedin a compartment in the welding housing. As can be appreciated, manyother arrangements can be designed to enable the air compressor to beelectrically connected to an external power source.

In accordance with still yet another and/or alternative aspect of thepresent invention, the electric air compressor can be energized fromeither the electrical generator in the engine welder housing or from anexternal power source. The ability for the air compressor to beenergized from multiple energy sources enhances the versatility of theair compressor. When the air compressor is designed to be powered frommultiple energy sources, the engine welder typically includes anelectric circuit that is used to manually or automatically select thepower source to be used by the air compressor. When the circuit includesa manual power selector, the selector is typically in the form of aswitch; however, other types of manual selectors can be used. In thisarrangement, the operator manually selects whether the air compressor isto receive power from the power generated from the engine welder orpower from an external source. The manual selector is then oriented oractivated by the user to cause the electric circuit to direct power tothe air compressor from the source selected by the user. When theelectrical circuit is designed to automatically select a power sourcefor the air compressor, the electrical circuit can be designed in manydifferent ways. In one non-limiting circuit design, the circuit sensesone or more of the available power sources that can be used to power theair compressor and then selects the power source. For instance, thecircuit can be designed to detect whether the engine welder isgenerating power, and if so, cause some of the generated power to bedirected to the air compressor. This same circuit can also be designedto electrically connect the air compressor to an external power sourceif the circuit does not detect power being generated by the enginewelder. A circuit can be also designed to select one available energysource over another. For instance, a circuit can be designed to detectwhether multiple power sources are available to power the aircompressor, and if so, automatically select one power source overanother. As can be appreciated, an electrical circuit that automaticallyselects a power source could include an manual override selector toallow a user to select a particular power source for powering the aircompressor. The above examples of electrical circuits is exemplary only,and in no way limits the many circuit designs that can be used tomanually, semi-automatically or automatically select a power source topower the electrical air compressor.

In accordance with a further and/or alternative aspect of the presentinvention, the air compressor assembly includes an electric motor, acompressor unit driven by the electric motor, and a compressed airreceiver or accumulator tank can be at least partially mounted in thehousing and be connected to the compressed air output of the aircompressor unit. The receiver tank is used to store compressed air. Ascan be appreciated, a plurality of receiver tanks can be positioned inthe housing of the engine welder. When a receiver tank is used, one ormore pressure monitors are typically used to monitor the pressure in theone or more receiver tanks. The monitor is designed to at leastpartially monitor the pressure in the receiving tank. In onenon-limiting design, the pressure monitor can be designed to send asignal when the detected pressure falls below a preset value and/orrises above a preset value. In this design, the signal generated by thepressure monitor can be used to activate the motor of the air compressorassembly when the detected pressure is too low or stop the motor whenthe detected pressure reaches a desired value or is too high. A pressuregauge can be positioned on the housing of the engine welder (e.g., frontpanel) to enable a user to monitor or read the current pressure level inthe receiver tank. The air pressure assembly also includes a pressurevalve that is typically designed to be connected to a hose of an airpowered tool or device; however, the pressure valve can be designed toalternatively or additionally connected to other devices. Typically, thepressure valve is a typical valve used in association with aircompressor equipment; however, any type of air pressure valve can beused. The pressure valve is typically located on the front panel of thewelder housing; however, the valve can be positioned in other locations.The pressure valve can be designed to send a signal when the pressurevalve opens or closes. This signal can be used to at least partiallycontrol the activation or deactivation of the motor of the compressorassembly.

The principal object of the present invention is to provide an enginewelder that can supply power to welding equipment and compressed air tovarious types of air tools.

Another object of the present invention is to provide an engine welderthat is more convenient and easier to operate.

Still another and/or alterative object of the present invention is toprovide an engine welder which is easier to set up and/or transport tovarious locations.

Yet another and/or alterative object of the present invention is toprovide an engine welder which is easy to assemble, easy to connect thewelding accessories of a welder to the housing, easy to connect the airtools to the housing, and/or easy to transport the welding accessoriesand/or air tools along with the engine welder to various locations.

Still yet another and/or alternative object of the present invention isto provide an engine welder that includes an air compressor.

A further and/or alternative object of the present invention is toprovide an engine welder that includes an electric powered aircompressor that is simple, reliable and durable to use, and whichelectric air compressor can be ergonomically positioned in the housingof the engine welder.

Still a further and/or alternative object of the present invention is toprovide an engine welder that includes a electric powered air compressorwhich is powered by the electric generator in the engine welder and/orby an external power source.

Yet a further and/or alternative object of the present invention is toprovide an engine welder that includes a pressure monitoring system thatmonitors and/or controls the pressure in one or more components of theengine welder.

These and other objects and advantages of the invention will becomeapparent to those skilled in the art upon reading and following thisdescription taken together with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference may now be made to the drawings which illustrate variousembodiments that the invention may take in physical form and certainparts and arrangements of parts wherein:

FIG. 1 is a perspective view of an assembled engine welder in accordancewith the present invention;

FIG. 2 is a partial cut away view of the side of the engine welder ofFIG. 1;

FIG. 2A is another partial cut away view of the side of the enginewelder of FIG. 1 without a plug for an external power source;

FIG. 3 is a partial cut away view of the top of the engine welder ofFIG. 1;

FIG. 4 is an electrical schematic of the relationship between theelectric generator and the electric air compressor; and,

FIG. 5 is a block diagram illustrating the air compressor system of theengine welder of FIG. 1.

DESCRIPTION OF PREFERRED EMBODIMENTS

Referring now to the drawings, wherein the showings are for the purposeof illustrating the preferred embodiments of the invention only and notfor the purpose of limiting the same, FIGS. 1-3 illustrate oneembodiment of the invention. Specifically, these figures illustrate aself-contained, portable and fully-integrated welder/generator andcompressor unit 100 in accordance with the present invention. Unit 100includes a housing 110 that having a top portion 112, two side portions114, 116, a back side 118 and a front panel 130. The welding housing isdesigned to encase at least a portion of the internal components of theengine welder. Positioned in the top portion 112 of welding housing 110is an exhaust pipe 150. The top of the housing typically includes one ormore fluid accesses 152, 154 to add coolants, lubricants, etc. to theengine located in the housing. The top of the housing also typicallyincludes a lift device 156 having an opening 158. The lift device isused to lift and/or move the engine welder by use of a crane or similarapparatus. A grommet 160 is also located on the top portion of thehousing. A fuel cap 170 is used to close the opening into the fillertube that is used to fill the fuel tank of the engine welder. An engineaccess panel 120 is located on side 114 of the housing. The access panelallows a user access to the serviceable components of the engine. Theaccess panel to connected to hinges 122 to enable the panel to beopened. A latch or handle 124 is used to open and close the accesspanel. One or more sides of the housing include air vents 126 to allowair flow through the housing so as to facilitate in cooling the internalcomponents of the housing. Housing 110 can include one or morecompartments, not shown, that provide a storage area for welding tools,nail guns, electric saws, lights, etc.

The front face or panel 130 of housing 110 also includes a vent 138 thatallows for air flow within the housing. The front panel also includesvarious switches, knobs, indicator lights and meters and gauges 132,134, 136 to monitor and/or control the operation of the welder/generatorand compressor unit. The front panel also includes electrical connectors142, 144 to connect a welding gun and/or other electrical equipment tothe welder/generator and compressor unit. Typically the front faceincludes at least one 120 volt connector and at least one 240 voltconnector; however, other combinations can be used (e.g., two 120connectors, two 240 volt connectors, etc.). As can be appreciated, thevoltage rating can be other than 120 and/or 240 volts (e.g. 230V, 277V,380V, 400V, etc.). As can be further appreciated, one or more voltconnectors can be positioned on the front face and/or other locations onthe welder/generator and compressor unit. The front panel and/or one ormore other regions of the welder/generator and compressor unit caninclude one or more features of the welder/generator and compressorunit, e.g., an on/off key slot, a start button for the internalcombustion engine, one or more circuit breakers, a light, voltage and/orcurrent meters, welding current settings, warning indicators, etc. Onenon-limiting designs for the front panel of the engine welder is similarto that of the RANGER series of engine welders offered by The LincolnElectric Company. As can be appreciated, many other configurations canbe used based on desired aesthetics of the front panel, engine welderfunctions, etc.

The front panel of the housing also includes an air compressor switch148 to activate and deactivate the air compressor. A compressed airoutlet 149 is positioned on the front panel to supply compressed air tovarious types of air power tools (e.g., nail gun, paint gun, pressurewasher, sand blaster, etc.). As can be appreciated, more than onecompressed air outlet can be positioned on the front panel. As can alsobe appreciated, one or more compressed air outlets can be located onother regions of the housing. In addition, the air compressor switch canbe located in other regions of the housing. An air pressure gauge can bepositioned on the housing to provide information on the pressure levelof the air being expelled from the compressed air outlet.

Contained within the housing 110 is an internal combustion engine 180that is mounted at one end of the housing 110. The internal combustionengine is typically provided with an air cleaner, a muffler 182, anexhaust pipe 184, an oil filler tube 188 and a battery (not shown) tostart the engine. A radiator 190 and fan 192 are included in the housingto cool the engine are also typically provided in the housing. Coolanttubes 194 allow the coolant to flow from the radiator into the engine.The coolant access 152 on the top of the housing allows a user to addcoolant and/or monitor the coolant level in the radiator. A fuel tank200 located in the base of the housing supplies fuel to the engine.Typically, the fuel tank is secured to the bottom of the housing.Positioned on the top region of fuel tank 200 is a filler tube 210 whichextends upwardly from the fuel tank and to a tube access opening 212 inthe top of housing 110. The filler tube and the fuel tank are shown tobe made of a one-piece material; however, the filler tube can beconnected to the fuel tank in other arrangements (e.g. weld, solder,adhesive, etc.). The filler tube is also illustrated as being formedfrom a single piece of material; however, the filler tube can be formedfrom multiple components. The fuel tank and filler material can be madeof the same or different materials. The filler tube includes a topportion 214 and a bottom portion 216. The base of the filler tube has alarger cross-sectional area than top of the filler tube. Thecross-sectional shape of the filler tube is shown to be generallyrectangular. The bottom portion of the filler tube has a larger diameterrectangular cross-sectional area than the rectangular cross-sectionalarea of the top portion. A majority of the bottom portion of the fillertube is shown to have a substantially constant cross-sectional area.Close to the top region of the bottom portion, the cross-sectional areatapers downwardly at a transition area until obtaining the size of thecross-sectional area of the top portion. The cross-sectional area of thetop portion is illustrated as being substantially uniform along thecomplete longitudinal length of the top portion. As a result, the bottomportion of said filler tube has a cross-sectional area that is greaterthat any region in the top portion of the filler tube. As can beappreciated, other cross-sectional shapes can be used for the top and/orbottom portion of the filler tube. The large cross-sectional area andvolume of the bottom portion of the filler tube is designed to reducethe rate at which the fuel rises in the filler tube after the fuel tankhas been filled. The reduced rate that the fuel rises in the filler tubeduring the filling of the filler tube with fuel allows an operator moretime to terminate the flow of fuel into the filler tube once theoperator is notified or learns from the fuel level indicator that thefuel tank is filled.

As best shown in FIGS. 1 and 2, the top of the filler tube extendsthrough the access opening on the top of the housing and through grommet160. Grommet 160 is inserted into tube access opening 212 and seals thetube access opening to inhibit or prevent fluids from entering theinterior of the housing. The grommet is also designed to direct fuelthat inadvertently spills into the grommet to a side of the enginewelder. The grommet is generally a one-piece structure made of aflexible material such as rubber. As can be appreciated, the grommet canbe a multi-piece structure that is connected together by various means(e.g. heat, adhesive, etc.). Grommet 160 includes a base surface 162 anda side wall 164 that extends about the outer perimeter of the grommet.The base surface and side wall form an internal cavity in the grommet. Atube opening is positioned in the base surface of the grommet. The shapeof the tube opening is selected to enable the top of the filler tube toextend through the tube opening and to form a seal about the fillertube. Typically the tube opening closely matches the cross-sectionalshape of the top of the filler tube or top fill section that extendsthrough the tube opening. The grommet can be secured in the accessopening in a variety of ways. Grommet 160 is shown as including a lip166. The lip is illustrated as partially curving over a side of thehousing of the engine welder. The lip is designed to direct fluids thathave inadvertently spilled into the grommet internal cavity to flowoutwardly from the cavity and over the side of the side of the housing.As such, the lip facilitates in the flow of fluids from the internalcavity of the grommet. The grommet can be designed so that when thegrommet is secured in tube access opening, the base surface of thegrommet slopes downwardly toward the lip. The sloped base surface causesfluids which have inadvertently spilled into the internal cavity of thegrommet to flow out of the internal cavity and onto the lip and thenover the side of the housing. The sloped surface also causes the fluidflowing from the internal cavity of the grommet to accelerate as thefluid approaches the lip. The faster moving the fluid facilitates in thefluid flowing over the lip.

A fuel level monitor is typically used to indicate the level of fuel inthe fuel tank. The fuel level monitor includes a fuel gauge 146 locatedon the front panel of the housing and a fuel level sensor (not shown)located in the fuel tank and/or filler tube. The fuel lever sensor isdesigned to measure one or more fuel levels in the fuel tank. The fuellevel sensor can be designed to use mechanical, chemical and/orelectrical means to detect a fuel level. The fuel level indicatorprovides the operator with information on the amount of fuel left infuel tank, thereby providing the operator with information to determinewhether a particular operation should be started and completed prior tothe fuel in the fuel tank being exhausted. If an operator determinesthat the operation will take more time than the amount of fuel in thefuel tank can provide to run the engine, the operator can re-fill thefuel tank prior to operation so that the operation does not have to beprematurely terminated and restarted due to the engine running out offuel. The fuel gauge can include a light to illuminate when one or moredetected fuel levels in the fuel tank and/or filler tube are detected,or illuminate when the fuel level monitor is in operation. A audiblealarm (not shown) can be included on the housing. The audible alarm,when used, is designed to make a sound when one or more detected fuellevels in the fuel tank and/or filler tube are detected. The audiblealarm can be designed to generate different sounds and/or sound levelsfor different detected fuel levels. The audible alarm can include alight to illuminate when one or more detected fuel levels in the fueltank and/or filler tube are detected. The light, like sound, is used todraw the operator's attention to the fuel gauge. The audible alarm isused to draw an operator's attention to the fuel gauge so as to notifythe operator that a particular fuel level in the fuel tank has beenreached and/or exceeded. During the fuel of the engine welder, theoperator may become distracted. The audible alarm is useful in regainingthe attention of the operator during the fueling process so that propermonitoring of the level of fuel in the fuel tank occurs during thefueling process. As can be appreciated, the audible alarm can be used asa back up monitor in the instances wherein the fuel gauge fails orprovides an inaccurate fuel level reading. The fuel level monitor, whenused, can be electrically powered and/or be mechanically operated. Whenthe fuel level monitor is electrically powered, the fuel level monitorcan be can powered by the electricity generated by the engine welderduring operation of the engine welder and/or powered by a alternative oradditional power source (e.g., battery, solar cell, fuel cell, etc.).

Referring again to FIGS. 2 and 3, an electric current generator 230 ismounted within the housing 110. The electric current generator isconnected to internal combustion engine 180 by a motor shaft 232. Themotor shaft is typically directly connected to electric currentgenerator 230; however, a gear box and/or belt drive, not shown, can beinserted therebetween to control and/or regulate the speed at which theelectric current generator is operated by internal combustion engine180. In one particular, non-limiting arrangement, internal combustionengine 180 is a water cooled and/or air cooled engine. The engine isdesigned to operate at a nominal speed of 1800 RPM with a 4-polegenerator design or 3600. RPM with a 2-pole generator design. Theauxiliary power provided by the electric current generator is normallyabout 60 hertz so as to be able to run standard power tools and lights.As can be appreciated, other sized engines and/or alternators can beused. Engine 180 typically includes an auxiliary drive output shaft 196.A primary drive 198 is typically connected to the cooling fan 192. Thecooling fan can be driven by an electric fan motor 220 that is connectedto the fan by a fan belt 222. As shown in FIG. 3, the housing is dividedinto several sections by internal wall partitions 240, 242, 244. Thepartition walls provide structural strength to the housing and dividethe internal components of the housing from one another. The division ofthe internal components by the partition walls also can be used toprotect the components from one another. Partition wall 240 divides thesection containing the combustion engine from the section containing theelectric generator. Motor shaft 232 passes through an opening inpartition wall 240. Typically located in the same section as theelectrical generator is the electrical circuitry used to generate thearc currents of the engine welder through electrical connectors 142 and144. As shown in FIG. 3, wires 242, 244 supply power to electricalconnector 144 and wires 246, 248 supply power to electrical connector142. As can be appreciated, one or more electrical circuits can belocated on other regions in the housing. A contact connector/switch 300is also positioned in the section between partitions 240, 242. Contactconnector/switch 300 is used to receive an internal plug 260 from motor252 of air compressor 250. The contact connector/switch is electricallyconnected to the electric generator. Typically the power from theelectric generator is 120V or 240V power for the electric motor 252. Ascan be appreciated, the contact connector/switch can be located in adifferent area within the housing.

The air compressor 250 is mounted within housing 210 between partitions242 and 244 as illustrated in FIG. 3. The air compressor includes anelectric motor 252 that drives a compressor 254. One or more airaccumulator tanks 256 are fluidly connected to compressor 280. The airaccumulator tanks are positioned in the housing; however, this is notrequired. A pipe or hose 258 conveys air from the compressor to the airaccumulator tank as shown in FIG. 5. As illustrated in FIG. 2, electricmotor 252 is electrically connected to receptacle 300 by a plug 260.Electric motor 252 can be alternatively or additionally powered by anexternal powered source via electric plug 260. The cord 272 of plug 260is shown to extend through the top of housing 110. As can beappreciated, the cord can extend through the housing in other regions ofthe housing. As can also be appreciated, plug 260 and cord 272 can bestored in a compartment in the housing (not shown). The use of plug 260allows a user to operate the air compressor without having to start andoperate engine 180 of the engine welder. FIG. 2A illustrates an enginewelder similar to FIGURE expect that plug 260 is only connected to theinternal power source of the engine welder. As can be appreciated, theengine welder can be designed such that plug 260 is only connectable toan external power source.

The air compressor typically includes a pressure monitor 280 that isused to monitor the air pressure in one or more of the air accumulatortanks. A pressure gauge (not shown) can be positioned on the front panelof the housing to provide the user information as to the pressure levelin the one or more of the air accumulator tanks. The air compressor alsoincludes a pressure valve 290 that can be used to regulate the flow ofair into and/or out of the one or more of the air accumulator tanks. Asshown in FIG. 5, the pressure monitor can be designed to generate asignal that is used to control the operation of motor 252 and/orpressure valve 290. In one non-limiting design, the pressure monitorgenerates a signal to the contactor 282 to electrically disconnect themotor 252 when a certain pressure level is detected in the airaccumulator tanks 256. Such an arrangement can facilitate in inhibitingor preventing over-pressurization of the air accumulator tanks 256. Inanother non-limiting design, the pressure monitor generates a signalcontactor 282 to electrically connect to motor 252 when a certainpressure level is detected in the air accumulator tanks 256. Such asarrangement can facilitate in inhibiting or preventing underpressurization of the air accumulator tanks 256 during the use of an airpowered tool. FIG. 5 also illustrates that pressure valve 290 can sendand/or receive a signal from contactor 282 and/or pressure monitor 280.In one non-limiting design, the pressure valve generates a signal tocontactor 282 to electrically connect to motor 252 when the valve isopened. Such as arrangement can facilitate in inhibiting or preventingunder pressurization of the air accumulator tanks 256 during the use ofan air powered tool. In another non-limiting design, the pressure valvereceives a signal to and from contactor 282 and/or pressure monitor tocause the pressure valve to open. Such an arrangement can facilitate ininhibiting or preventing over-pressurization of the air accumulatortanks 256 when the pressure monitor detects a certain pressure level inthe air accumulator tanks. As can be appreciated, may other oradditional control systems can be used to maintain the desired pressurelevel in the air accumulator tanks.

One basic arrangement for the connection of the air compressor to theelectric generator of the engine welder is illustrated in FIG. 4. Theelectric generator includes two windings 234, 236 that can be used togenerate a 120V or 240V output. The output from the electric generatoris directed to a circuit breaker (e.g. two pole breaker). The circuitbreaker is connected to air compressor switch 148 that is located on thefront panel of the housing. Although not shown in FIG. 4, plug 260, whenused, is typically electrically connected between the electric generatorand the air compressor switch. Referring again to FIG. 4, when theswitch is turned on, the electric power from the electric generator isdirected to receptacle 300. Plug 260 is connected to receptacle 300. Thecurrent flowing through plug 260 is used to energize motor 252 of aircompressor 250. A pressure switch 280 is associated with compressor 254and is used to activate or deactivate motor 252 to maintain the desiredor acceptable amount of pressure in tanks 256.

It will be appreciated that the present invention provides aself-contained, portable and fully integrated unit 100 that can beeasily and conveniently transported to various work sites for use inwelding, providing auxiliary electric power, and/or providing compressedair. In addition, the housing of the internal combustion engine,electric alternator, and the air compressor results in a noise levelreduction, thereby improving the work environment. Furthermore, thecombined welder and air compressor in the housing facilitates in thequick and easy connection and removal of welding equipment, electricalequipment and/or air tools on the housing.

The invention has been described with reference to a preferredembodiment and alternatives thereof. It is believed that manymodifications and alterations to the embodiments disclosed readilysuggest themselves to those skilled in the art upon reading andunderstanding the detailed description of the invention. It is intendedto include all such modifications and alterations insofar as they comewithin the scope of the present invention.

1. An integrated welder, generator and compressor unit comprising: a. ahousing that at least partially contains components of said welder,generator and compressor; b. an engine at least partially mounted insaid housing; c. an electric current generator at least partiallymounted in said housing and at least partially connected orinterconnected to said engine to be at least partially driven thereby;d. an electric air compressor at least partially mounted in saidhousing, said electric air compressor able to be at least partiallypowered by the current generated by said electric current generator whenelectrically connected to said electric current generator during theoperation of said engine; and, e. an electric plug that is detachablyconnectable to a receptacle, said electric plug electrically connectedto said electric air compressor, said receptacle electrically connectedto said electric current generator.
 2. The unit as defined in claim 1,wherein said electric air compressor is able to be at least partiallypowered by a power source external to said integrated welder.
 3. Theunit as defined in claim 2, including an electric circuit that controlspower to said air compressor between said electric current generator andsaid power source external to said integrated welder.
 4. The unit asdefined in claim 2, wherein said electric plug is designed to bedetachably connected to said external power source external to saidintegrated welder, said electric plug positioned on an exterior surfaceof said housing, positioned in a compartment that is accessible from theexterior surface of said housing, on an electric cord that is positionedin a compartment that is accessible from the exterior surface of saidhousing, or on an electric cord that is extending from the exteriorsurface of said housing.
 5. The unit as defined in claim 3, wherein saidelectric plug is designed to be detachably connected to said powersource external to said integrated welder said electric plug positionedon an exterior surface of said housing, positioned in a compartment thatis accessible from the exterior surface of said housing on an electriccord that is positioned in a compartment that is accessible from theexterior surface of said housing, or on an electric cord that isextending from the exterior surface of said housing.
 6. The unit asdefined in claim 1, including a receiver tank at least partially mountedin said housing, said receiver tank fluidly connected to said aircompressor.
 7. The unit as defined in claim 5, including a receiver tankat least partially mounted in said housing, said receiver tank fluidlyconnected to said air compressor.
 8. The unit as defined in claim 6,including a pressure monitor to monitor a pressure in said receivertank.
 9. The unit as defined in claim 7, including a pressure monitor tomonitor a pressure in said receiver tank.
 10. The unit as defined inclaim 8, wherein said pressure monitor generates a control signal toactivate or deactivate said air compressor based at least partially on adetected air pressure level in said receiver tank.
 11. The unit asdefined in claim 9, wherein said pressure monitor generates a controlsignal to activate or deactivate said air compressor based at leastpartially on a detected air pressure level in said receiver tank. 12.The unit as defined in claim 1, including an air pressure gauge on anexterior surface of said housing.
 13. The unit as defined in claim 11,including an air pressure gauge on an exterior surface of said housing.14. The unit as defined in claim 1, including a compressed air access onan exterior surface of said housing, said air access designed to beconnected to an air powered accessory.
 15. The unit as defined in claim13, including a compressed air access on an exterior surface of saidhousing, said air access designed to be connected to an air poweredaccessory.
 16. The unit as defined in claim 1, including a pressurevalve, said pressure valve generating a control signal when saidpressure valve is open or closed, said control signal at least partiallycontrolling the activation or deactivation of said air compressor. 17.The unit as defined in claim 15, including a pressure valve, saidpressure valve generating a control signal when said pressure valve isopen or closed, said control signal at least partially controlling theactivation or deactivation of said air compressor.
 18. The unit asdefined in claim 1, wherein said air compressor is located in a frontsection of said housing and rearward of a front panel of said housing.19. The unit as defined in claim 17, wherein said air compressor islocated in a front section of said housing and rearward of a front panelof said housing.
 20. The unit as defined in claim 1, wherein said powergenerated by said generator is a substantially constant voltage sourcethat is usable by said air compressor.
 21. The unit as defined in claim19, wherein said power generated by said generator is a substantiallyconstant voltage source that is usable by said air compressor.
 22. Theunit as defined in claim 1, wherein said housing includes at least oneelectrical outlet for use by welding equipment and at least one airoutlet for use by air powered tools.
 23. The unit as defined in claim21, wherein said housing includes at least one electrical outlet for useby welding equipment and at least one air outlet for use by air poweredtools.
 24. The unit as defined in claim 1, wherein said housing includeswheels to enable said housing to be rolled over a ground surface. 25.The unit as defined in claim 23, wherein said housing includes wheels toenable said housing to be rolled over a ground surface.
 26. A method ofproviding compressed air from an integrated welder comprising: a.providing a housing that is at least partially contains an engine atleast partially mounted in said housing; b. providing an electriccurrent generator that is at least partially mounted in said housing andis at least partially connected or interconnected to said engine to beat least partially driven thereby; c. providing an electric aircompressor at least partially mounted in said housing, said electric aircompressor able to be at least partially powered by the currentgenerated by said electric current generator when electrically connectedto said electric current generator during the operation of said engine;and d. providing an electric plug that is detachably connectable to areceptacle, said electric plug electrically connected to said electricair compressor, said receptacle electrically connected to said electriccurrent generator.
 27. The method as defined in claim 26, including thestep of at least partially powering said air compressor by a powersource external to said integrated welder.
 28. The method as defined inclaim 26, including the step of at least partially powering said aircompressor by a power source external to said integrated welder.
 29. Themethod as defined in claim 27, including the step of at least partiallypowering said air compressor by a power source external to saidintegrated welder.
 30. The method as defined in claim 26, wherein saidelectric plug is designed to be detachably connected to said powersource external to said integrated welder, said electric plug positionedon an exterior surface of said housing, positioned in a compartment thatis accessible from the exterior surface of said housing on an electriccord that is positioned in a compartment that is accessible from theexterior surface of said housing, or on an electric cord that isextending from the exterior surface of said housing.
 31. The method asdefined in claim 29, wherein said electric plug is designed to bedetachably connected to said power source external to said integratedwelder, said electric plug positioned on an exterior surface of saidhousing, positioned in a compartment that is accessible from theexterior surface of said housing, on an electric cord that is positionedin a compartment that is accessible from the exterior surface of saidhousing, or on an electric cord that is extending from the exteriorsurface of said housing.
 32. The method as defined in claim 26,including the step of providing a receiver tank at least partiallymounted in said housing, said receiver tank fluidly connected to saidair compressor.
 33. The method as defined in claim 31, including thestep of providing a receiver tank at least partially mounted in saidhousing, said receiver tank fluidly connected to said air compressor.34. The method as defined in claim 26, including the step of monitoringa pressure in said receiver tank.
 35. The method as defined in claim 33,including the step of monitoring a pressure in said receiver tank. 36.The method as defined in claim 34, including the step of generating acontrol signal based upon a detected pressure in said receiver tank toactivate or deactivate said air compressor.
 37. The method as defined inclaim 35, including the step of generating a control signal based upon adetected pressure in said receiver tank to activate or deactivate saidair compressor.
 38. The method as defined in claim 26, including thestep of providing an air pressure gauge on an exterior surface of saidhousing.
 39. The method as defined in claim 37, including the step ofproviding an air pressure gauge on an exterior surface of said housing.40. The method as defined in claim 26, including the step of providing acompressed air access on an exterior surface of said housing, said airaccess designed to be connected to an air powered accessory.
 41. Themethod as defined in claim 39, including the step of providing acompressed air access on an exterior surface of said housing, said airaccess designed to be connected to an air powered accessory.
 42. Themethod as defined in claim 26, including the step of providing powergenerated by said generator that is a substantially constant voltagesource for use by said air compressor.
 43. The method as defined inclaim 41, including the step of providing power generated by saidgenerator that is a substantially constant voltage source for use bysaid air compressor.
 44. The method as defined in claim 26, wherein saidhousing includes at least one electrical outlet for use by weldingequipment and at least one air outlet for use by air powered tools. 45.The method as defined in claim 43, wherein said housing includes atleast one electrical outlet for use by welding equipment and at leastone air outlet for use by air powered tools.
 46. The method as definedin claim 26, wherein said housing includes wheels to enable said housingto be rolled over a ground surface.
 47. The method as defined in claim45, wherein said housing includes wheels to enable said housing to berolled over a ground surface.